Solute and phase heterogeneous distribution at different scales and its effect on ageing physical phenomena in a laser powder bed fusion produced maraging steel

The Laser Powder Bed Fusion process involves complex thermodynamic and heat transfer mechanisms which results in a complicated understanding of the material’s microstructure and phase transformation processes. In the case of additive manufacturing maraging steels, these present heterogeneous structures which mainly consist of Body-Centred Tetragonal (BCT) martensite and retained austenite (Face-Centred Cubic (FCC) phase structure), unlike conventionally processed material. Research has already been done on the competitive or collaborative nature of austenite growth/reversion and precipitation in these materials. However, for Laser Powder Bed Fusion maraging steels, studies have focused on either the effect of the heterogeneous structures on austenite reversion kinetics or the formation, evolution and behaviour of precipitation. Still, no comprehensive research exists that covers in detail the relation between solute heterogeneity from the meso- to the nanoscale and its influence on both phase distribution and ageing physical phenomena. To do so, multiscale chemical analyses and microstructural characterisation techniques were used to investigate a maraging steel M300 in different transformed conditions: as-built, aged at 480 and 540 °C. The results showed that competing mechanisms during printing caused segregation at the mesoscale, which remains in aged samples. Vaporisation led to Cr segregation, while melt convections caused Ni and Ti depletion at melt pool boundaries. Retained austenite location was found at melt pool boundaries and away from them on the as-built structure. Its preferential location remains unclear. Dissimilarities from conventional material were identified in nanosized clustering and precipitates on aged samples.